Corrosion degradation and interface behaviour of magnetron sputtered NiAl coatings doped with Zr, Hf, and Cr

IF 7.4 1区 材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY
Shen Tao , Hui Peng , Hongbo Guo
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Abstract

In this work, NiAl-based coatings doped with optimised Zr, Hf, and Cr content are deposited via magnetron sputtering and evaluated for hot corrosion performance. Systematic high-temperature corrosion tests and microstructural analyses reveals that the corrosion resistance and oxide scale adherence of the coatings are strongly dependent on the dopant type and content. Among the single-element doped coatings, NiAlZr exhibits the highest corrosion resistance but suffers from poor scale adhesion, whereas NiAlCr shows the lowest corrosion resistance yet excellent adhesion due to the formation of porous internal and external oxide layers. NiAlHf coating demonstrates intermediate performance. Mechanistically, Zr/ZrO2 particles effectively suppress the β→γ/γ′ phase transformation and stabilise the grain structure, while HfO2 promotes interfacial transitions that improves scale anchoring. The presence of Cr will reduce the lattice mismatch but potentially disrupted γ′ ordering. Furthermore, surface wettability and roughness are observed to govern salt mist deposition behaviour, with smoother, more hydrophobic coatings (NiAlZr and NiAlHf) resisting salt accumulation. Notably, a significant synergistic effect between Zr and Hf identified in co-doped NiAlZrHf coating, which outperforms the single-doped counterparts. These findings offer insights into compositional tailoring strategies for enhancing hot corrosion resistance in advanced aluminide coatings.
掺杂Zr、Hf和Cr的磁控溅射NiAl涂层的腐蚀降解和界面行为
在这项工作中,通过磁控溅射沉积了掺杂优化Zr, Hf和Cr含量的nial基涂层,并评估了热腐蚀性能。系统的高温腐蚀试验和显微组织分析表明,涂层的耐蚀性和氧化垢附着力与掺杂剂的种类和含量密切相关。在单元素掺杂涂层中,NiAlZr具有最高的耐蚀性,但结合力较差,而NiAlCr由于形成多孔的内外氧化层,具有最低的耐蚀性,但结合力较好。NiAlHf涂层性能中等。机制上,Zr/ZrO2颗粒有效抑制β→γ/γ′相变,稳定晶粒结构,而HfO2颗粒促进界面转变,改善尺度锚定。Cr的存在会减少晶格错配,但可能会破坏γ′的顺序。此外,观察到表面润湿性和粗糙度控制盐雾沉积行为,更光滑,更疏水的涂层(NiAlZr和NiAlHf)抵抗盐积聚。值得注意的是,共掺杂NiAlZrHf涂层中发现了Zr和Hf之间的显著协同效应,优于单掺杂涂层。这些发现为提高高级铝化物涂层的耐热腐蚀性能的成分定制策略提供了见解。
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来源期刊
Corrosion Science
Corrosion Science 工程技术-材料科学:综合
CiteScore
13.60
自引率
18.10%
发文量
763
审稿时长
46 days
期刊介绍: Corrosion occurrence and its practical control encompass a vast array of scientific knowledge. Corrosion Science endeavors to serve as the conduit for the exchange of ideas, developments, and research across all facets of this field, encompassing both metallic and non-metallic corrosion. The scope of this international journal is broad and inclusive. Published papers span from highly theoretical inquiries to essentially practical applications, covering diverse areas such as high-temperature oxidation, passivity, anodic oxidation, biochemical corrosion, stress corrosion cracking, and corrosion control mechanisms and methodologies. This journal publishes original papers and critical reviews across the spectrum of pure and applied corrosion, material degradation, and surface science and engineering. It serves as a crucial link connecting metallurgists, materials scientists, and researchers investigating corrosion and degradation phenomena. Join us in advancing knowledge and understanding in the vital field of corrosion science.
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